Raised access floor

ABSTRACT

A modular raised access floor panel includes a frame, a first edge member, a second edge member, and a center member. The first edge member has a first floor surface. The second edge member is disposed substantially perpendicular to the first edge member and has a second floor surface. The first center member is disposed adjacent to the first edge member and has a third floor surface. When the floor panel is assembled, the first floor surface, the second floor surface, and the third floor surface are disposed substantially within the same plane.

RELATED APPLICATIONS

This application is related to and claims priority from Provisional U.S. Patent Application Ser. No. 60/759,465 filed Jan. 17, 2006, for an Extruded and Die-Cast Aluminum Raised Access Floor, with inventors Peter J. Spransy and Brian Mazur, which is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to flooring. More specifically, the present invention relates to raised-access floors.

BACKGROUND

Raised access flooring systems have been used for decades in areas of buildings that require frequent access to the space underneath the floor. Typically used in computer labs and cleanroom areas, the space underneath the access floor is generally used to route pipes, electrical wires, and signal lines. Often the area under the floor is also used to return air that comes into the room via filters in the ceiling. To provide easy access, the floor may be made up of floor panels, typically two feet square, which may be supported on pedestal stands. Removing a single panel or a number of panels may thus allow access. Equipment may be either placed directly on the floor or if extremely heavy supported on separate stands. Recently in the microchip industry, the equipment in cleanrooms has become significantly heavier, causing building operators concern when moving in new equipment. If a heavily loaded floor panel breaks, the expensive equipment might be significantly damaged.

The typical die-cast aluminum floor panel generally has two main limitations: first, the actual materials used and second, an inefficient structural design.

First, the alloying materials used in the die-cast aluminum may cause the material properties to be relatively brittle compared to wrought or extruded aluminum alloys. This typically gives the material low resistance to impact loading. In addition, the very nature of the die-casting process may induce impurities, inclusions, small gas pockets and other material irregularities that may reduce the strength in general and may greatly increase the variability of the strength properties. This is generally compensated for by using a larger design factor of safety than that used for wrought aluminum.

Second, with die-casting, it may be necessary to design draft into the part being produced so the cast part can be ejected from the die. Draft typically means that every surface of the cast piece is tapered so it will release from the die after molding. In the case of the panel design, this typically means that the structural ribs are tapered so that the bottom of the ribs is thinner than where the ribs join the top plate surface. This is usually inefficient since to resist bending loads in the panel there should be generally more material at the bottom, i.e., to get an I-beam effect.

Attempts have been made to produce welded panels from extruded shapes but the cost to manufacture this style has generally precluded their adoption. Steel floor panels have also been used sporadically, however, they are usually excessively heavy, making them difficult to place and remove by one person and are not typically recognized as cleanroom compatible since any scratches in the finished surface could eventually rust becoming a source of contaminates. Steel panels are also typically very difficult and costly to cut in the field.

Therefore, a need exists for a raised access floor that is strong, lightweight, and less expensive to manufacture.

SUMMARY OF THE INVENTION

[SUMMARY OF THE CLAIMED INVENTION—TO BE COMPLETED AFTER THE CLAIMS ARE FINALIZED]

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only exemplary embodiments and are, therefore, not to be considered limiting of the invention's scope, the exemplary embodiments of the invention will be described with additional specificity and detail through use of the accompanying drawings in which:

FIG. 1 is an exploded perspective view of an embodiment of a raised access floor panel;

FIG. 2 is a perspective view of another embodiment of a raised access floor panel;

FIG. 3 is a perspective view of a further embodiment of a raised access floor panel;

FIG. 4 is a bottom perspective view of the embodiment of a raised access floor panel as shown in FIG. 3;

FIG. 5 is a bottom view of the embodiment of a raised access floor panel as shown in FIG. 3;

FIG. 6 is a perspective view of an embodiment of a raised access floor system;

FIG. 7 is a perspective view of the embodiment of a modular raised access floor system shown in FIG. 6 with a supported load; and

FIG. 8 is a perspective view of the embodiment of a modular raised access floor system shown in FIG. 6 with a supported load where some of the center members have been moved from the disposition of FIG. 7 and positioned near the supported load.

DETAILED DESCRIPTION

Various embodiments of the invention are now described with reference to the Figures, where like reference numbers indicate identical or functionally similar elements. The embodiments of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of several exemplary embodiments of the present invention, as represented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of the embodiments of the invention.

The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.

While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

FIG. 1 is an exploded perspective view of an embodiment of a modular raised access floor panel 100. The modular floor panel 100 may be assembled from edge members 102, corner members 104 and a center member 106. The edge members 102 may form the circumference (or frame) of the modular floor panel 100. The edge members 102 may include a floor surface 103. The edge members 102 may be extruded. The edge members 102 may be made of aluminum.

Edge members 102 that are extruded and/or made of aluminum may provide several advantages over die-cast and/or aluminum parts. For example, die-cast aluminum is typically brittle and unpredictable, generally requiring employing a larger safety factor, which is inefficient. Overloaded die-cast aluminum may fail quickly and catastrophically. Extruded aluminum is generally ductile and may have higher impact resistance. When overloaded, extruded aluminum will generally yield in bending, giving warning of overload. Extruded aluminum may bend and even be permanently damaged but will often not fail.

In another example, die-cast material may need to be cut to create specialty floor panels for pass-throughs, vacuum ports, electrical connections, and other unique requirements. Cutting die-cast material often results in a compromised floor panel and may result in inadequately supported panel loads. Additionally, welding die-cast material may be very unreliable and may consequently render a welded floor panel structurally undependable.

In comparison to die-cast material, extruded material may be welded very easily. This may facilitate welding suitable reinforcement onto the panel which may reestablish a permanent structural design after the panel has been modified. Furthermore, specialty panels may be cast into the center member 106 of the panel 100 and/or the center member 106 may be removable creating an access hatch in the floor panel 100. Unusual size panels, i.e., rectangular panels, may also be easily fabricated, which is typically not possible from existing die-cast panels.

Modular floor panels 100 that include edge members 102 may provide an advantage over entirely die-cast floor panels, because producing a new die-casting die typically includes exorbitant costs and long lead-times. In embodiments where the edge members 102 are extruded, preparing a new extrusion die is typically minimal in comparison. Furthermore, when the edge profiles 102 are extruded rather than die-cast with the center member 106, the die-cast portions of the floor panel 100 may be reduced, which may reduce the size of the parts to be die-cast. Reductions in the size of the parts to be die-cast may significantly reduce the cost of manufacture and installation.

The edge members 102 may be essentially rectangular tubes in shape. The edge members 102 may include cavities 112. In embodiments where the edge members 102 are rectangularly shaped tubes, the edge members 102 may form a box-beam at the full perimeter where bending stresses are highest. This may give the edge members 102 a high strength to weight ratio. This provides a further advantage over die-cast edge members because die-cast parts typically require draft so that the cast part may release from the die. Draft may limit the amount of load that can be applied to a floor whether such loads are stationary loads or loads caused by equipment move-in. Making the entire panel from die-cast material may weaken the floor system because the edge of the floor panel is typically the weakest part of the panel particularly when supporting a rolling load that is passing over the edge of one panel onto another.

In other embodiments, the edge members 102 may also include ribs (not shown) and/or pretension cabling to increase the strength of the panel 100. This may provide a strengthening option that may not restrict the space beneath the panel 100, unlike simply increasing the depth of the panel 100.

The center member 106 may form the center section of the panel 100. The center member 106 includes a floor surface 107. The center member 106 may be made of aluminum and/or die-cast. The center member 106 may include a pattern of apertures 108. In some embodiments, the apertures are integrally formed with the center member 106. The apertures 108 may provide sufficient open area to facilitate airflow. For example, in a cleanroom application, the apertures 108 may allow a user to take advantage of the space underneath the floor panel 100 for the return of filtered air. The apertures 108 may be drilled, die-cast with the center member 106, and/or otherwise formed. In embodiments where the apertures 108 are drilled into a die-cast center member 106, drilling may be simplified because drilling a die-cast center member 106 may generate granular shavings versus the long stringy shavings typically generated while drilling an extruded center member 106.

The corner members 104 may include floor surfaces 105. The corner members 104 may include ears 110. The ears 110 may be press-fit into the cavities 112 of edge members 102 forming a rectangular or square outer frame. The corner members 104 may be die-cast and/or aluminum. Each of the corner members 104 may be shaped substantially identically such that they are interchangeable and may be positioned at any corner of the frame.

The edge members 102 may include a support ledge 114. When used opposite each other, the support ledges 114 may provide support for the center member 106. Because the center member 106, of the present embodiment, does not interlock with the edge members 102, it is removable. This may provide the advantage of being able to first assemble the edge members 102 and corner members 104 and then place the center members 106 into place. This may make installation by a single installer possible. In other embodiments, the center member 106 may be fixed to at least one support ledge 114. The center member 106 may be fixed to a support ledge 114 by, for example, screws. Fixing the center member 106 to a support ledge 114 may help to prevent rattling between the center member 106 and other components of the floor panel 100.

In the present embodiment, when fully assembled, the floor surfaces 103 of the edge members 102, the floor surfaces 105 of the corner members 104, and the floor surface 107 of the center member 106 may be disposed substantially within the same plane.

FIG. 2 is a perspective view of another embodiment of a modular raised access floor panel 200. The floor panel 200 of the present embodiment is similar to the previously described floor panel 100, because it may be assembled from edge members 202, which are essentially rectangular tubes in shape, and corner members 204. The center member 206 forms the center section of the panel 200. The center member 206 may include integral full depth ribs to create slotted perforations 208 instead of apertures 108. The slotted perforations 208 may be longer than the apertures 108, which may provide more airflow through the slotted perforations 208 than the apertures 108. The center member 206 may include small ribs (not shown) that may add stiffness between the larger full depth ribs (not shown). Another embodiment that uses integral full depth ribs and small ribs is shown in FIG. 4.

The edge members 202 may include a floor surface 203. The corner members 204 may include floor surfaces 205. The center member 206 may include a floor surface 207. In the present embodiment, as assembled, the floor surfaces 203 of the edge members 202, the floor surfaces 205 of the corner members 204, and the floor surface 207 of the center member 206 may be disposed substantially within the same plane.

In other embodiments, the edge members 202 may have tongue and groove interlocking edges (not shown), which may eliminate the need for welding the basic panel. In the present embodiment, the edge members 202 are made of aluminum and/or extruded. The corner members 204 and/or the center members 206 may be die-cast and/or aluminum.

Referring to FIGS. 3, 4 and 5, FIG. 3 is a perspective view of a further embodiment of a modular raised access floor panel 300; FIG. 4 is a bottom perspective view of the floor panel 300; FIG. 5 is a bottom view of the floor panel 300. The floor panel 300, in the present embodiment, may be similar to the previously described floor panels 100, 200, because it may be assembled from edge members 302, 330 and corner members 304. The edge members 302, 330 may essentially be rectangular tubes in shape. The edge members 302, 330 may be cut to length. Two of the edge members 330 may be longer than the other two edge members 302.

Additionally, a cross member 332 may be positioned near the middle of the longer edge members 330. The cross member 332 may include support ledges 340 that may support the center members 306. Likewise, the edge members 302, 330 may have support ledges 314.

The cross member 332 may be attached using bolts, may simply rest on the support ledges 314 of the longer edge members 330, may rest on the support ledges 314 and be bolted to the longer edge members 330, and/or may be attached using other attachment methods. There are myriad methods for connecting the cross member 332 to the longer edge members 330 to create a support for the center members 306.

In embodiments where two of the edge members 330 are longer than the other two edge members 302, the modular raised access floor panel 300 may be used with open waffle slab subfloors. Typically, an elaborate under floor substructure may be required to support the square floor pedestals when used in conjunction with open waffle slab subfloors. Because two of the edge members 330 are longer than the other two edge members 302, the floor panel 300 may span across the openings in the concrete slab potentially eliminating the need for any additional substructure.

Further, two center members 306 may form the center section of the panel rather than the single center members 106, 206 of the previous embodiments. The top surface of the center members 306, shown in FIG. 3, may include apertures 308 similar to FIG. 1. These apertures 308 may be combined with integral full depth ribs 320. The center member 306 may include small ribs 322 that may add stiffness between the larger full depth ribs 320.

The edge members 302, 330 may be extruded and/or aluminum. The corner members 304 and/or the center members 306 may be die-cast and/or aluminum. The edge members 302, 330 may include a floor surface 303. The corner members 304 may include floor surfaces 305. The center members 306 may include floor surfaces 307. In the present embodiment, the floor surfaces 303 of the edge members 302, 330, the floor surfaces 305 of the corner members 304, and the floor surfaces 307 of the center members 306 may be disposed substantially within the same plane.

These floor panels 100, 200, 300 may be modular, with center panels 106, 206, 306 that may be easily removed and/or replaced. The modular floor panels 100, 200, 300 may be supported on pedestals (not shown) that leave space between the structural floor and the assembled floor panels 100, 200, 300. Floor panels 100, 200, 300 in the USA are typically 24 inches by 24 inches square. In embodiments with two center members 306, the floor panels 100, 200, 300 may be 48 inches by 24 inches square. In two center member 306 embodiments, the cross member 332 may have substantially twice the width as an edge member 102. In further embodiments, multiple edge members 102, multiple center members 106, and/or multiple cross members 332 may be used to create larger floor panels 100. For example, a floor panel 100 with four center members 106 may be contemplated.

FIG. 6 is a perspective view of an embodiment of a modular raised access floor system 450. The modular raised access floor system 450 may include multiple floor panels 100, 400. The floor panels 100, 400 may be assembled from edge members 102, corner members 104 and center members 106, 406. In some embodiments, the center members 106, 406 may be die-cast. Some center members 106 may include apertures 108. Other center members 406 may not include apertures 108. In other embodiments, the center members 206 (shown in FIG. 2) may include slotted perforations 208 and/or other apertures.

The center members 106, 406 may be modular. The edge members 102 may form the circumference (or frame) of the modular floor panels 100, 400.

The floor panels 100, 400 may be supported by pedestals 460. The pedestals 460 may secure the corner members 104 together. The pedestals 460 may secure the corner members 104 using bolts and/or other securing methods.

In some embodiments, the modular raised access floor system 450 may include a covering after being fully assembled. For example, a vinyl covering may be used to give the floor system 450 a smooth surface for rolling loads and/or other purposes.

FIG. 7 is a perspective view of the embodiment of a modular raised access floor system 450 shown in FIG. 6 with a supported load 470. As shown in FIG. 7, the perforated center members 106 are not located around the supported load 470. Rather, non-perforated center members 406, which may not allow for the passage of a significant amount of air, are positioned under and around the supported load 470. In cleanroom applications, airflow may be generally directed near machinery, if desired. In FIG. 7, the airflow may be generally directed away from the supported load 470 and toward the lower edge of the floor system 400 because the non-perforated center members 406 are positioned under and around the supported load 470.

FIG. 8 is a perspective view of the embodiment of a modular raised access floor system 450 shown in FIG. 6 with a supported load 470 where some of the center members 106, 406 have been moved and positioned near the supported load 470. The floor system 450 shown in FIG. 8 may provide more airflow directed toward the supported load 470 because some of the non-perforated center members 406 that were positioned around the supported load 470, as shown in FIG. 7, have been replaced with perforated center members 106. Airflow may be further increased by replacing the non-perforated center members 406 and/or perforated center members 106 that are positioned near the supported load 470 with perforated center members 206 (shown in FIG. 2) having slotted perforations 208.

Because cleanroom layouts and equipment may be routinely changed, in embodiments where the center members 106 are removable, the modular raised access floor system 450 may provide simpler modification of the floor's airflow without disrupting walls (not shown) that are usually located on the joints between panels, which would remain in place. This may avoid the problem of moving walls and/or portions of walls when the panel to be removed lies under the wall.

Furthermore, because the center members 106 are removable, the total weight of the floor panels 100 may be significantly reduced. This may reduce installation costs because a job that otherwise may require two workers, based on weight restrictions and/or fatigue, may generally be accomplished by one worker. The modular nature of the center members 106, 206, 306, 406 may also permit early installation of floors and walls which may prevent installation delays based on the final airflow requirement determinations, because, while these determinations are being made, the installer may assemble the edge profiles 102 and corner members 104.

While specific embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise configuration and components disclosed herein. Various modifications, changes, and variations, which will be apparent to those skilled in the art, may be made in the arrangement, operation, and details of the methods and systems of the present invention disclosed herein without departing from the spirit and scope of the invention. 

1. A modular raised access floor panel comprising: a frame, comprising: a first extruded edge member having a first floor surface; and a second extruded edge member disposed substantially perpendicular to the first extruded edge member and having a second floor surface; a first die-cast center member disposed adjacent to the first extruded edge member and having a third floor surface; and wherein the first floor surface, the second floor surface, and the third floor surface are disposed substantially within the same plane.
 2. The modular raised access floor panel of claim 1, wherein the first extruded edge member further comprises a support ledge and the first die-cast center member rests on the support ledge.
 3. The modular raised access floor panel of claim 2, wherein the second extruded edge member further comprises a support ledge and the first die-cast center member rests on the support ledges of the first and second extruded edge members.
 4. The modular raised access floor panel of claim 1, wherein the first die-cast center member further comprises a plurality of apertures.
 5. The modular raised access floor panel of claim 4, wherein the plurality of apertures comprise slotted perforations.
 6. The modular raised access floor panel of claim 4, wherein the plurality of apertures are die-cast with the die-cast center member.
 7. The modular raised access floor panel of claim 4, wherein the plurality of apertures are drilled into the die-cast center member.
 8. The modular raised access floor panel of claim 1, wherein the first die-cast center member further comprises a plurality of support ribs.
 9. The modular raised access floor panel of claim 8, wherein the plurality of support ribs comprises a plurality of full-length support ribs and a plurality of less than full-length support ribs.
 10. The modular raised access floor panel of claim 1, further comprising a corner member.
 11. The modular raised access floor panel of claim 10, wherein the corner member further comprises a first ear and a second ear.
 12. The modular raised access floor panel of claim 11, wherein the first extruded edge member further comprises a cavity and the second extruded edge member further comprises a cavity.
 13. The modular raised access floor panel of claim 12, wherein the first ear of the corner member press-fits into the cavity of the first extruded edge member and the second ear of the corner member press-fits into the cavity of the second extruded edge member.
 14. The modular raised access floor panel of claim 1, further comprising an extruded cross member disposed substantially perpendicular to the first extruded edge member and having a fourth floor surface and wherein the fourth floor surface is disposed substantially within the same plane as the first, second, and third floor surfaces.
 15. The modular raised access floor panel of claim 14, wherein the extruded cross member further has support ledges.
 16. The modular raised access floor panel of claim 15, further comprising a second die-cast center member disposed adjacent to the extruded cross member and the second die-cast center member rests on one of the support ledges of the extruded cross member.
 17. The modular raised access floor panel of claim 16, wherein the first and second die-cast center members each further comprise a plurality of apertures and the plurality of apertures in the second die-cast center member are different from the plurality of apertures in the first die-cast center member.
 18. The modular raised access floor panel of claim 1, wherein the raised access floor panel is comprised of aluminum.
 19. A modular raised access floor panel comprising: a first edge member comprising a cavity and a support ledge; a second edge member disposed substantially perpendicular to the first edge member, comprising a cavity and a support ledge; a first center member disposed adjacent to the first edge member and having a third floor surface, the first center member comprising a plurality of apertures; a second center member disposed adjacent to the first edge member and having a fourth floor surface, the second center member comprising a plurality of apertures; a cross member positioned between the first center member and the second center member and having a fifth floor surface, the cross member comprising a plurality of support ledges; wherein the first floor surface, the second floor surface, the third floor surface, the fourth floor surface, and the fifth floor surface are disposed substantially within the same plane; wherein the first center member rests on the support ledge of the first edge member, the support ledge of the second edge member, and at least one of the plurality of support ledges of the cross member; and wherein the second center member rests on the support ledge of the first edge member and at least one of the plurality of support ledges of the cross member.
 20. A modular raised access floor assembly comprising: a plurality of modular raised access floor panels each comprising: a plurality of edge members, the plurality of edge members comprising a first floor surface, a cavity, and a support ledge; a center member disposed adjacent to at least one of the plurality of edge members having a second floor surface, the center member comprising a plurality of apertures; a plurality of corner members comprising a third floor surface, a first ear, and a second ear; wherein the center member rests on at least one of the support ledges of the plurality of edge members; and wherein the first ear of at least one of the plurality of corner members press-fits into the cavity of one of the edge members and the second ear of that corner member press-fits into the cavity of another edge member; wherein the first floor surfaces, the second floor surface, and the third floor surfaces are disposed substantially within the same plane; and wherein at least two of the plurality of corner members are connected.
 21. The modular raised access floor assembly of claim 20, wherein one of the center members is the same structure as another center member. 